Raypak 259 Installation & Operating Instructions Manual Download Page 46

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Summary of Contents for 259

Page 1: ...al switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas sup plier s instructions If you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or the gas supplier This manual should be maintained in legible condition and kept adjacent to the heater o...

Page 2: ...M Free Chlorine MUST NOT EXCEED 5 PPM Occasional chemical shock dosing of the pool or spa water should not damage the heater providing the water is balanced Automatic chemical dosing devices and salt chlorinators are usually more efficient in heated water unless controlled they can lead to excessive chlorine level which can damage your heater and which is not covered under warranty A check valve s...

Page 3: ...essure Relief Valve Installation 26 Electrical Wiring 27 Transformer Wiring 28 Optional Left Hand Wiring 28 Plumbing Water Connections 32 Wiring Diagram 33 General Location of Controls 34 Control Adjustments 34 Control Panel Removal 35 Thermostat Operation Direct Spark Board 37 Status and Diagnostics 38 Remote Control Installation and Operation 38 Remote Operation 38 Activating the Remote 39 Remot...

Page 4: ...nstallation to ensure proper securing and sealing WARNING Altering any Raypak pressure vessel by installing replacement heat exchangers tube bundle headers or any ASME parts not manufactured and or approved by Raypak will instantly void the ASME and or CSA ratings of the vessel and any Raypak warranty on the vessel Altering the ASME and or CSA ratings of the vessel also violates national state and...

Page 5: ...ufficient purging may keep the heater from lighting on the first try 6 Double check gas connections make sure no leaks are present Use soapy water to inspect 7 Double check incoming electrical power verify suf ficient output voltage to the heater 8 The unit comes wired for 240V 1ph 60Hz power If the supply voltage is nominally 120V 1ph 60Hz switch the blower harness located inside the cabi net see...

Page 6: ...during spa or hot tub use can cause drowsiness which could lead to unconsciousness and subsequently result in drowning 3 Pregnant Women Beware Soaking in water over 102 F 39 C can cause fetal damage during the first three months of pregnancy resulting in the birth of a brain damaged or deformed child Pregnant women should stick to the 100 F 38 C maximum rule 4 Before entering the spa or hot tub us...

Page 7: ...will settle on the ground Since propane can accumulate in confined areas extra care should be exercised when lighting propane heaters WARNING Should overheating occur or the gas supply fail to shut off turn off the manual gas control to the heater ...

Page 8: ...THER OPERATION IMPORTANT FREEZE INFORMATION COLD CLIMATE Prolonged operation with water temperatures below 50 F is not recommended When starting the heater with water temperatures below 50 F operate the heater continuously until higher temperatures are reached Operating the heater for prolonged periods with pool water below 50 F can seriously damage the heater and is not cov ered by the warranty F...

Page 9: ...a box in the carton with the heater STANDARD UNIT 1 Plastic pipe finish flange for gas line 6 2 2 CPVC Ring Nuts 2 Bonding lug with mounting screw 7 2 O rings 3 2 CPVC Slip x Slip 8 3 16 Nipple 8 2 2 CPVC tail pieces 4 2 CPVC Slip x Slip 7 Nipple 9 2 3 1 2 Vinyl Grommets 5 2 2 CPVC PVC unions with O rings Be sure that you receive the number of packages indicated on the Bill of Lading When ordering...

Page 10: ...AN CSA B149 Installation Codes and Canadian Electrical Code CSA C22 1 Part 1 and Part 2 SECTION 2 GENERAL SPECIFICATIONS These heaters are design certified and tested under the latest requirements of the ANSI Z21 56 CSA 4 7 Standard for Gas Fired Pool Heaters All heaters can be used either indoor or outdoors Ambient Temperature Rating of Heater Components Electronic Ignition Heater 32 F to 175 F R...

Page 11: ...Back 1 Front Alcove Open Right Side 1 Vent 1 Left Side 1 Floor 0 OUTDOOR INSTALLATION TOP EXHAUST Top Unobstructed Outdoor Stack Floor 0 Right Side 8 Back 6 Left Side 8 OUTDOOR INSTALLATION REAR EXHAUST Top Unobstructed Floor 0 Right Side 8 Back 12 Left Side 8 Clearance from top of vent terminal Do not install on carpeting When installed according to the listed minimum clear ances from combustible...

Page 12: ...to any building The top surface of the heater shall be at least 3 ft above any forced air inlet or intake ducts located within 10 ft horizontally For installations in Canada pool heaters shall not be installed with the top of the vent assembly within 10 ft below or to either side of any opening into the building Refer to the latest revisions of CAN CSA B149 4 ft Minimum 4 ft Minimum 1 ft Minimum 4...

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Page 14: ...el number BR 409 EN X indicates a unit with digital IID ignition using natural gas with bronze headers and cupro nickel tubes 2 Ratings are for natural gas and elevations up to 2 000 feet above sea level For elevations over 2 000 feet consult the factory 3 Flue gases must be properly vented with CAT I vertical venting or CAT III horizontal venting Non metallic venting not acceptable Inlet air can ...

Page 15: ...ing 3 ft 91 cm K Clearance to mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3m horizontally 6 ft 1 83m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 13m 7 ft 2 13m t M Clearance under veranda porch deck or balcony 12 in 30 cm TT 1 In accordance with the current ANSI Z223 1 NFPA 54 National Fuel Gas Code 2 In accordance with the current CAN CSA ...

Page 16: ...unit for combustion 1 Install combustion air direct vent in accordance on page 21 horizontal or page 22 vertical of this manual 2 Provide adequate ventilation of the space occupied by the heater s by an opening s for ventilation air at the highest practical point communicating with the outdoors a In the US the total cross sectional area shall be at least 1 in 2 of free area per 20 000 BTUH 111 mm2...

Page 17: ...suitability of a vent material for application on a Category III or IV vent system Using improper venting materials can result in personal injury death or property damage VENTING Venting Category Requirements Combustion Air Supply Exhaust Configuration Heater Venting Category Certified Materials Combustion Air Inlet Materials From Inside Building Vertical Venting I B Vent Equivalent Horizontal Thr...

Page 18: ...rminate vent in window well stairwell alcove courtyard or other recessed area NOTE During winter months check the vent cap and make sure no blockage occurs from build up of snow or ice 10 DO NOT terminate above any door window or gravity air intake Condensate can freeze causing ice formations 11 Locate or guard vent to prevent condensate from damaging exterior finishes Use a rust resistant sheet m...

Page 19: ...s or chimneys vent installations shall be in accordance with the NFGC U S or B149 Canada or applicable provisions of local building codes Natural Draft Vertical Venting Category I Fan Assisted Installation Natural draft venting uses the natural tendency of the heated flue gases to rise until they are expelled from the top of the flue The negative draft must be within the range of 01 to 08 in WC as...

Page 20: ...our elbows The vent cap is not considered in the overall length of the venting system The connection from the appliance vent to the stack must be as direct as possible The horizontal breach ing of a vent must have an upward slope of not less than 1 4 inch per linear foot from the heater to the vent terminal The horizontal portions of the vent shall also be supported for the design and weight of th...

Page 21: ...pe or vent cap material are allowed Such substitutions would jeopardize the safety and health of inhabitants Direct Vent Horizontal Through the Wall Installation These installations utilize the heater mounted blower to draw combustion air from outdoors and vent com bustion products to the outdoors The total length of the through the wall flue cannot exceed 80 equivalent ft in length for the flue o...

Page 22: ...The direct vent cap cannot be installed in a well or below grade The direct vent cap must be installed at least 1 ft above ground level and above normal snow levels The direct vent cap MUST NOT be installed with any combustion air inlet directly above a direct vent cap This vertical spacing would allow the flue products from the direct vent cap to be pulled into the combus tion air intake installe...

Page 23: ...ion to Stackless Rear Exhaust 992 VENT or 1 800 992 8368 in the US or 1 888 SEL KIRK or 1 888 735 5475 in Canada Protech System Inc 800 766 3473 Z Flex 800 654 5600 or American Metal Products 800 423 4270 Pipe joints must be positively sealed Follow the vent man ufacturer s installation instructions carefully Outdoor Installation The stackless top provided with the heater is the stan dard venting ...

Page 24: ...and no load conditions with no more than a 30 pressure drop between static pressure and full load The factory manifold pressure settings should be 0 40 0 1 WC for either natural or propane gas SUPPLY PRESSURES sidered are a It reduces the chance of water infiltration espe cially in snowy areas b It relieves lot line restrictions c It is easier to service the heater Care must be taken when locating...

Page 25: ... 0 28 5 125 28 0 30 0 INTERNAL AUTOMATIC BYPASS VALVE A built in automatic bypass valve is provided in the in out header The internal bypass valve automatical ly responds to changes in water flow in the piping sys tem Proper amount of water is maintained through the heater under varying flows dictated by the condi tions of the pump and filter BYPASS SPRING BYPASS VALVE An auxiliary bypass valve sh...

Page 26: ...wired for 240 VAC power supply DO NOT attempt to oper ate with a 208 VAC nominal supply CAUTION Heater must be electrically grounded and bonded Bonding lug is provided loose with the heater Install bonding lug on lower right or left side of jacket as necessary for bonding the heater Mounting hole is provided on the jacket The Electronic Intermittent Ignition Device automati cally lights the main b...

Page 27: ...nnection or using a two or three wire remote See pages 38 40 If using a switched GFCI power source the heater post purge func tion will be bypassed adversely affecting heater operation and life NOTE If the transformer s primary side is wired for 120 VAC and 240 VAC is applied damage to the trans former and PC board may result Such damages are not covered under manufacturer s limited warranty WARNI...

Page 28: ...el and replace with the plug from the left hand side 6 Route supply lines from the left side and through the provided loops under the control panel see image 7 See provided wiring tag for correct connection points 8 Reinstall the junction box cover when completed PLUG RIGHT SIDE PANEL ROUTE SUPPLY LINES THROUGH PROVIDED LOOPS PULL WIRES THROUGH LEFT SIDE PANEL Optional left hand wiring STANDARD RI...

Page 29: ...steps make sure that all electrical power to the heater has been turned OFF LEFT INLET RIGHT OUTLET PLUMBING 1 Remove thermostat sensor from Jaco fitting and set aside 2 Remove Inlet CPVC Ring Nut and Plug 3 Relocate and tighten CPVC Ring Nut and Plug to the right side of the In Out Header 4 Reroute and install the thermostat sensor to the right side of the In Out Header RIGHT INLET LEFT OUTLET PL...

Page 30: ...TION AND IS NOT INTENDED TO REPLACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER THIS DIAGRAM IS RAYPAK S RECOMMENDATION AND IS NOT INTENDED TO REPLACE AN ENGINEERED PIPING SYSTEM BY A PROFESSIONAL ENGINEER POOL HEATER WITH INTERNAL BYPASS POOL HEATER WITH INTERNAL BYPASS Single Pool or Spa Heater Installation Multiple Pool or Spa Heaters Installation ...

Page 31: ...ust be located so that any water leaks will not damage the structure of adjacent area PVC pipe may be glued directly into header unions CAUTION An additional source of heated water e g a solar system must be connected to the main line ahead of the heater inlet pipe in order for it to act as the primary heat source If the primary system provides adequate heat to maintain set point the heater will n...

Page 32: ...32 WIRING DIAGRAM ...

Page 33: ...T ACCESS PANEL BONDING LUG LOCATION TEMPERATURE SENSOR AIR PRESSURE SWITCH VENT PRESSURE SWITCH PRV LEFT ACCESS PANEL BONDING LUG LOCATION OPTIONAL DRAIN VALVE HL1 HL2 HIGH LIMITS T P GAUGE FLOW SWITCH TRANSFORMER BLOWER RELAY WIRING BOX SUPPLY POWER GAS VALVE GAS ORIFICE GAS CONNECTION 3 4 NPT ...

Page 34: ...nt door to access wire harnesses 3 Reaching underneath the PC board carefully remove all connectors and wires from the PC board and ON OFF toggle switch 4 Lift the front bezel lid and remove the two lower Phillips screws 5 Carefully lift the control panel upwards and pull away from the heater 6 The control panel can now be flipped around to remove or inspect the PC board 7 Reverse procedure for re...

Page 35: ...DE and UP buttons simultaneously for 3 to 5 seconds The heater will continue to operate normal ly while in the Service Menu The first screen dis played is the Flame Strength indicator which indicates MODE TEMP LCD Display Temp Buttons Mode Button ALTERNATING DISPLAYS DURING HEATING FLAME STRENGTH INDICATOR SUPPLY VOLTAGE INDICATOR RUN TIME INDICATOR Press the DOWN button The Supply Voltage screen ...

Page 36: ... Fahrenheit temperatures The UP or DOWN buttons will select Fahrenheit or Celsius on the temperature display Choose the desired temperature scale Spa Max Temp Spa Set Point Maximum Adjustment Refer to step one above to access the program screen Press the MODE button until Spa Max Temp appears on the digital display Using the UP and DOWN buttons will change the Maximum Temperature Setting to your d...

Page 37: ...in gas valve output is not in com manded state Internal Fault Board fault replace board EEPROM Fault Memory fault Cycle power and reset set points Replace board if fault does not clear Clock Fireman Sw Time clock fireman switch circuit is open Low Temp Lockout Water temperature below 36 F The following heat status messages are displayed in Pool Spa and Remote modes when there are no active fault c...

Page 38: ...y the remote wiring Typically a remote does not supply power to the heater it only provides a switching function to turn the heater On or Off If your remote is supplying its own voltage to the heater it will not work with this heater and may damage the digital circuit board For operation of the heater using the onboard thermo static controls with a time clock see the Time Clock Fireman s Switch se...

Page 39: ...he control The actual setpoint will be con trolled by the remote control 4 Turn the mode button to OFF and remove power from the heater 5 On the Remote Interface Harness connect the BLUE wire to one side of the REMOTE switch and con nect the other side to either the ORANGE BLACK wire for SPA operation or the BLACK ORANGE wire for POOL operation 6 Attach wire nut on unused wire to the Remote Interf...

Page 40: ...not cov ered by warranty Do not exceed 50ft of total wiring using 18 AWG stranded copper wire rated for 105ºC 221ºF mini mum NOTE When using a time clock the heater will dis play Clock Fireman Sw when the fireman s switch is open indicating that the time clock has shut off the call for heat HIGH LIMITS This standard dual purpose control mounted and wired in series with the main gas valve shuts off...

Page 41: ...ss than 0 26 along their entire length BRACKET O RING GAS ORIFICE Be sure that electrical service to the heater has prop er overload fuse or circuit breaker protection wire size and connections which comply with all applicable codes VISUAL INSPECTION ELECTRICAL Flames can be observed through the sight glass reflection below the blower motor A blue colored flame indicates normal operation At least ...

Page 42: ...damage Sooted heater Combustion fan not running Fan relay Fan 5 min Delay signal or Fan Fan Lockout signal Burned motor Air pressure switch Heater turns on for less Wiring than 4 seconds Incorrect supply wiring no display error PC Board short Ignition not sensed Clean igniter with wire brush Replace board if no strength signal is being detected Replace fan relay Loose connection or failed motor In...

Page 43: ...ister wires and connector at Terminal P1 Check resistance value of the thermister Reference to chart below Replace thermister if not within 10 of values shown below If okay replace Circuit Board Temp Degrees F 40 50 60 70 80 90 100 106 Resistance k 261 1 199 0 153 1 118 8 93 0 73 3 58 3 51 0 If okay replace Circuit Board Sensor resistance at various temperatures Water Sw Open Water flow switch Ver...

Page 44: ... S 17 S 18 S 20 S 2 J 23 S 26 S 9 C 8 C 1 J 19 S 14 S 3 S 3 C 5 M 6 M 10 C 4 S 5 H 2 H 1 M 2 M 6 C 7 C 6 H 5 S 1 F 5 F 6 F 1 P 2 P 2 F 3 F 4 F 25 S 9 M 15 S 24 S 11 M 4 C 2 C 8 V 1 R 4 R 2 R 4 H 7 H 3 R 5 R 12 H 3 H 9 H 10 H 11 H 15 H 14 H 5 C 13 H 16 H 1 C 17 H 18 H 20 H 19 H 21 H 22 H 14 M 7 V 9 V 11 C SECTION 6 REPLACEMENT PARTS ...

Page 45: ... standard company warranties must be properly tagged with a return parts tag completely filled in with the heater serial number model number etc and shipped to the Company freight prepaid If determined defective by the Company and within warranty a like part or equal substitution will be returned freight collect Credit will not be issued MANUFACTURER 2151 EASTMAN AVENUE OXNARD CA 93030 ...

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Page 47: ...e wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbo...

Page 48: ...www raypak com Raypak Inc 2151 Eastman Avenue Oxnard CA 93030 805 278 5300 Fax 805 278 5468 Litho in U S A 48 ...

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Raypak 259, Installation & Operating Instructions Manual

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